Machine pattern for a textile tufting machine

ABSTRACT

A textile tufting machine is controlled by a pattern produced by applying a grid to an artist&#39;&#39;s pattern equal to the number of tufts in the pattern then making a binary coded machine pattern gridded corresponding to the colors of the artist&#39;&#39;s pattern when gridded, sensing and decoding the machine pattern and thereby controlling the tufting machine needles accordingly. The pattern itself has a number of unit areas consisting of a number of rows and columns of binary coded information with the columns equal to the number of needles in the tufting machine and the rows equal to the number of needle strokes in a pattern.

O United States Patent n 1 3,568,614

[72] Inventors Stanley Shorrock; 3,247,815 4/1966 Polevitzky 112/79Norman Ian Buckley, Blackburn, England 3,433,188 3/1969 Pickles 112/79[21] Appl. No. 762,961 3,459,143 8/1969 Ellison et a1. 112/79 [22] FiledSept. 26, 1968 3,103,187 9/1963 Hammel 112/79 [45] Patented Mar-9,1971[73] Assignee Said Buckley assignor to said Sharrock L;1?: on 32]Priority Sept. 26 1967 E Great mitain Att0rneySughrue, Rothwell, Mion,Zmn & MacPeak [31] 47876/67 4 [5 1 PATTERN A TEXTILE TUFHNG ABSTRACT: Atextile tufting machine is controlled by a pat,

12 Chin, 5 Drawing Figs. tern produced by applying a grid to an artist'spattern equal to the number of tufts in the pattern then making a binarycoded [52] U.S.Cl 112/79 hi tt n gridded corresponding to the colors ofthe f D05C15/26 artists pattern when gridded, sensing and decoding the[50] Fleld ofSearch l machine pattern and [hereby controlling thetufting machine 79-5, needles accordingly. The pattern itself has anumber of unit 56 R f Cted areas consisting of a number of rows andcolumns of binary l 1 UNITE-11:82:38 QATENTS coded information with thecolumns equal to the number of needles in the tufting machine and therows equal to the 3,247,814 4/1966 Polevitzk 1 12/79 number of needlestrokes in a attern.

' PATENT ED "AR 91971 SHEET 1 BF 3 PATENTED MAR 9 I97! SHEET 2 OF 3 Ourinvention relates to the production of a pattern to be copied by amachine, the pattern concerned being more particularly suitable forcontrolling a textile machine such as a tufting machine, capable ofproducing a textured or colored carpet.

Patterns are known which control, for example, the pile height producedin such a machine, by forming an opaque design on a transparent base,illuminating the pattern from one side and deriving pattern informationfrom the other by photocell pickups. Whilst this is effective todistinguish between one of two states e.g. high or low pile, it is notsuitable toproduce piles of several lengths or colors since, moreparticularly in the latter case, some kind of color discriminating meansis necessary in connection with the pattern, and such means are usuallycomplicated and expensive.

We have devised a form of machine pattern in which the pattern isdivided into a number of units, each unit corresponding to a particulartuft to be applied to a backing material by a tufting machine. In eachunit we apply a marking determining the tuft length or color, and themarking is such that any one of several tuft lengths or colors may bechosen.

In one form of our invention, in order to provide a machine patternwhich is capable of producing a patterned fabric either of tufts ofvarying length without color discrimination in the machine, orvaricolored tufts, we arrange for an artist to produce a basic pattern.This pattern is then placed beneath a screen which is divided into anumber of horizontal rows and vertical columns, the columns being equalto the number of yarns to be applied across each pattern or patternrepeat on the base fabric, and the numberof rows being equal to thenumber of cycles of the machine during the completion of a singlelengthwise pattern or pattern repeat. The artist pattern, beneath aruled transparency, is then transferred to a typewriter type mechanism,and the operator presses a key for each particular artist pattern partseen through each transparency division or unit area. The typewritermechanism then applies blanking stripes to each unit of the transparencyin a code representing the information seen by the operator through thedivision. Thus for example each color could be represented by threeparts of each unit; each part may either be left transparent or blockedout, so'that a combination of 2 choices of color can be dealt with bythree parts. If only four colors are required, then only two parts ineach unit need be provided. The transparency contains means at its edgefor synchronizing it with the movement of the base fabric and the yarnsupplies of the machine, and such means may consist either of a seriesof bars printed on the transparency edge, or punched holes, or any othersimilar synchronizing means. A]- ternatively a punched-card-typemechanism could be employed.

When the transparency is applied to the machine, it is wrapped round atransparent drum, and illuminated from the inside along a linecorresponding to a row of tufts to be applied to the base fabric. Eachunit of the pattern is provided with three photocells, and thecombination of photocells illuminated by each unit determines via acomputer-type apparatus the color selected or the tuft height. Opticalmeans may be provided on the tufting machine for magnifying the machinepattern so as to enable the reproducing photocells to be spacedadequately apart and screened from one another.

if necessary, a pair of synchronized coded machine patterns may beemployed, one pattern code determining the color, and the other thelength, of each tuft.

Alternatively the machine pattern may be produced on a machine remotefrom the operators position and the pattern may be punched, not marked,as by placing a machine pattern base beneath the artist pattern, andpunching both. In the case of the remote machine, the pattern producedmay be the same size as the original or different, and the impressionsmay be delayed so as to enable the operator to correct a mistake.

Reference should not be made to the accompanying drawings in which:

FIG. ll shows the various ways in which each unit of a machine patterncan be marked,

FIG. 2 shows a typewriter mechanism adapted for producing a machinepattern from a colored original,

FIG. 2A is an enlarged view of a portion of HG. 2,

FIG. 3 shows the method of deriving information from the machine patternin order to control the colors applied to a carpet by a tufting machine,and

FIG. 4 shows the circuit of a decoding apparatus as used in conjunctionwith the machine pattern.

Referring now to FIG. 1, eight units of a pattern are shown. Each unitconsists of a rectangle, which is divided into three parts. Each partcan be white (or transparent) or black (or opaque). It therefore followsthat since the number of ways in which the parts can be filled in is 2each unit of pattern with three separate parts can control eightdifferent colors of yarn. The choice of unit parts filled in and theassociated colors are of course entirely arbitrary, and is predeterminedfor any particular group of colors to be used. Although a unit dividedinto three parts is shown, more or less parts could be used, in whichcase more or less colors of yarn could be controlled.

Each machine pattem is composed'of a large number of units, there beingrows and columns of units. 'Since each rug or carpet to be made would inall probability consist of pattern repeats both across and along thefabric, we arrange that the number of columns is equal to the number ofneedles used across each pattern repeat on the base fabric, and thenumber of rows are equal to the number of cycles of operation of themachine during the completion of a single lengthwise pattern repeat. Toproduce the number of pattern repeats required across the fabric, theneedles are grouped and each group is connected to its adjacentneighbor, so that one machine pattern controls several groups ofneedles.

FIGS. 2 and 2A show the method of making a machine pattern. We provide amodified typewriter mechanism as shown in FIG. 2, and assuming thateight color variations are required, eight color keys are provided,together with a carriage return key. Depression of any one key applies ablanking pattern to the unit concerned, and transfers the pattern oneunit row crosswise. A depression of the carriage return key moves thepattern up one column, and returns it to a start position.

In the drawings, the color keys are denoted by the numbers 1 to 8, andthe carriage return key is 9. The typewriter mechanism has a body 10, onwhich there is the usual platen roller 11. On the latter is placed acolored pattern 12 as designed by an artist, the artistpattemconstituting one section of a pattern repeat to be worked into a carpetor rug. On top of the pattern is placed a translucent machine patternsheet 13, and there is a fixed window 14 located at the center of themachine opposite the machine pattern 13. The latter is divided into agrid consisting of a number of units equal to the product of a number ofcolumns and rows in one pattern repeat, and the machine is designed sothat on depression of one of the keys 1 to 8, a blanking action takesplace through the window 14 whereafter the patterns move one columnwidth, with the roller 11.

In action, an operator inserts the artists and machine patterns in thebody 10 as shown in FIG. 2. She then brings the first unit of thepattern beneath the window and observes the color, thereafter depressingthe appropriate color key. This applies a blanking or blackeningmaterial to a required number of divisions of the pattern unitconcerned, and moves the roller and the two patterns one column spacealong, on restoration of the key. Observation of the second portion ofthe pattern through the second unit space now occurs, and the blankingaction is repeated. This continues to the'end of a line of columns,whereupon the carriage return key 9 is depressed, and the two patternsand roller are returned to the start of the next row. This actioncontinues until the whole of the artist's pattern has been transferredto the machine pattern. FIG. 2A shows a part of a machine pattern inwhich the units have been blanked or blacked-out in various manners. Oneof the blanking or blackening keys is shown at 15, and the blacking-outmay be effected either by inking each key before it moves into contactwith the machine pattern, or by the use of a typewriter ribbon.

In this connection it should be noted that although FIGS. 2 and 2A showthe preparation of the machine pattern whilst in contact with theartists pattern it should be recognized that this is not necessarily theonly method of performing the process of the invention. This particularmethod of preparing the pattern would provide a machine pattern whichwould be equal in size to that drawn by the artist. If however a veryconsiderable amount of color information is required on a machinepattern, it may be necessary to make this larger than the pattern drawnby the artist. In this case, a separate machine pattern producing deviceis employed. This consists of marking arrangements similar to that shownin MG. 2, but whereas in the previous arrangement the actual machinecopy was made on the artists pattern, in the modified arrangement, onlya unit grid is applied to the artists pattern. As before the operatordepresses keys in accordance with the colors seen through the unit grid,the difference being that electromag netic hammers or punches produce amachine pattern remotely from the machine operated by the operator. Thismachine pattern can be smaller, larger or the same size as that of theartists original sketch as determined by the dimensions of the machinepattern producing devicel In order to ensure synchronization between themachine pattern and the needle movements of the machine, the machinepattern is provided with synchronizing marks or holes along at least oneedge, and these marks may either actuate photocells or may cooperatewith cogs or spikes on the pattern drum of the tufting machine.

When the machine pattern has been produced, and it is required to usethis pattern to control a tufting machine, the machine pattern isapplied to a transparent drum which is mounted on a tufting machine, andthe drum is illuminated from inside. Alternatively the pattern may beopaque and each unit consist of white and black reflecting spaces, inwhich case the pattern is illuminated from the outside. in PEG. 3 thereis shown a machine pattern 20 on a drum 2i, one column of the pattern 22being devoted to synchronizing dots as shown. When placed in position onthe machine, the pattern drum rotates synchronously with the movement ofthe backing fabric.

Above the pattern is an arrangement of photosensitive cells 23, threesuch cells 27, 28, 29 being provided for each pattern unit area. Thecells are arranged in rows 24, 25, 26, across the width of the pattern.In use, each cell is energized or not by light from its own part of theunit instantaneously below it. The outputs of each group of three cellsare connected to a computer device 30, which decodes the information toa mark or energization on one of eight leads 31. There is a counter foreach group of photosensitive cells i.e., for each needle in a patternrepeat. Photoresistive cells are used i.e. cells whose resistance fallswhen light, infrared or ultraviolet radiation falls on them.

The computer itself the circuit of which is shown in FIG. 4 consists ofan integrated circuit with computer amplifiers, and will be describedlater. Each of the wires Bil is connected to a different yarn feed, eachwire being adapted when energized to feed its own particular color toits associated needle. On energization of one of the wires 31,appropriate control mechanism which does not form part of the presentinvention supplies a length of colored yarn to its particular needle sothat the machine repeats at each needle the color information derivedfrom the associated pattern unit via the photocells and computer. Afterthe appropriate colored yarns have been supplied to all the needles, thelatter are driven through the backing fabric leaving the colored tuftsin position, and the needles are retracted, whereupon the backing fabricand the pattern move one row along and the process is repeated until thewhole of the carpet or rug has been produced. Note that since the drum2]. is substantially endless, a strip of carpeting can be made of anyparticular length required, provided the uniform color.

H0. 4 shows the control circuit for each group of three photoresistivecells and the associated needle. The photocells are numbered 27, 28 and29, and each photocell is connected to the input of an associatedamplifier transistor 44, 45 or dd respectively. The outputs of thesetransistors are connected to the input terminals A, B and C respectivelyof an integrated circuit decoder of known type, the decoder operating soas to provide an output potential on one of the output terminals 511 to58 for each input code. These output terminals are connected viaisolating resistors to further amplifying transistors 61 to 68, and eachtransistor. operates a relay or control mechanism 71 to 78 which eitherdirectly supplies a colored yarn or operates a supply and cutoffmechanism of known type to do so. in view of the extremely smalldimensions and relatively low cost of the parts concerned, it is quitefeasible to supply this quantity of apparatus per needle, seeing thatthe result is the production of a multicolored patterned tufted carpetin a relatively cheap and straightforward manner, and using a machinepattern which is readily changeable to another pattern should this bedesired.

Although the machine pattern has been described as consisting of atransparent sheet consisting of a number of units of which parts may beblocked out, it should be understood that each unit may consist of anarea in an opaque sheet, and that portions of the area may be punchedout instead of blacked out, in which case feelers or means other thanphotocells may be employed in order to sense the punched-out portions.As a still further alternative, the machine pattern may be made byphotographic means, the pattern itself consisting initially of a sheetof photosensitive material on which the machine pattern is projected,unit by unit, under control of the operator, so as to expose some or allof the spaces in each unit. The pattern is then developed and fixed bynormal methods. This avoids the use of typewriter mechanisms andblanking ink.

It should be realized that production of a pattern consisting of aseries of binary coded units of this character is eminently suitable forpurely electromechanical control of the machine; in addition such abinary coded pattern may be connected directly to a computer which mayassess the amount of materials required for a given carpet, its cost,and other details.

We claim:

l. A machine pattern for a textile tufting machine comprising a basedivided laterally into a number of columns equal to the number ofneedles in the machine to be individually controlled, and longitudinallyinto a number of rows equal to the number of needle strokes in a patternon the finished carpet, the result being a number of unit areas ofpattern equal to the product of the said rows and columns, and aplurality of binary signalling parts in each unit.

2. A machine pattern as recited in claim 1, wherein said base istransparent and flexible with the parts of each unit area carrying abinary code of markings adapted alternatively to transmit or blockradiation.

3. A machine pattern as recited in claim l, wherein said base isreflective and flexible, the parts of each unit area carrying a binarycode of markings adapted alternatively to reflect or absorb radiation.

4. A machine pattern as recited in claim ll, wherein said base is opaqueand flexible, the parts of each unit area carrying a binary code punchedthrough said base.

5. A machine pattern as recited in claim 1, including a synchronizingmeans carried on at least one side thereof, the said means beingperiodically recurring signalling areas.

6. A method of producing and using a machine pattern as recited in claimll, including the steps of producing an artist's pattern, applying agrid to said artists pattern, said grid consisting of a number of unitareas equal to the product of the number of tufts in each row of atufted carpet pattern to be produced, and the number of columns ofstitches in said pattern, producing a machine pattern consisting of alike number of unit areas containingbinary coded informationcorresponding to said artist's pattern, passing said machine patternpast a plurality of sensing devices each of which senses the binary codeof a unit area at one time, decoding the outputs of said sensingdevices, and applying each decoded results to control the supply of yarnto one needle of a tufting machine.

7. A method as recited in claim 6, including the steps of producing acolored artists pattern, placing said grid with said pattern in anadapted typewriter mechanism, applying a binary code to the unit areasof said grid by means of said mechanism, and using said coded grid tocontrol the colors of yarns fed to the needles of said tufting machineto produce a tufted carpet with a pattern of tufts colored to correspondwith said artists pattern.

8. A method as recited in claim 6, including the steps of producing acolored artists pattern, placing said grid with said pattern in aprimary adapted typewriter mechanism, placing a machine pattern blank ina secondary mechanism synchronously operated with said primarymechanism, actuating said primary mechanism so as to produce a series ofbinary coded unit areas on said machine pattern blank, and controllingthe supply of colored yarns to the needles of said tufting machine bymeans of said coded machine pattern.

9. A method as recited in claim 6, characterized in that said machinepattern is transparent, with a binary code thereon of opaque parts, andincluding the steps of providing an illuminating means and a pluralityof photosensitive devices equal to the number of tufting machine needlesto be controlled, and passing said machine pattern between saidilluminating means and said photosensitive devices.

10. A method as recited in claim 6, wherein said machine pattern isreflective, with a binary code thereon of radiation absorbent parts, andincluding the steps of providing an illuminating means and a pluralityof photosensitive devices equal to the number of tufting machine needlesto be controlled, illuminating one side of said pattern by saidilluminating means, and sensing the radiation reflected from thereflecting parts thereof by means of said photosensitivedevices.

11. A method as recited in claim 6, wherein said machine pattern is anopaque sheet, and including the steps of punching said sheet in saidunitareas with a plurality of holes to produce a said binary codes.

12. A method as recited in claim 6, wherein said sensing devices arephotoresistive cells, an-integrated circuit and a transistor amplifiersconnections from said cells to said amplifiers and integrated circuit,said integrated circuit decoding the combination of signals receivedfrom said photoresistive cells to apply a potential to one of aplurality of output leads, the lead energized determining the color ofyarn to be fed to the associated tufting machine needle.

1. A machine pattern for a textile tufting machine comprising a basedivided laterally into a number of columns equal to the number ofneedles in the machine to be individually controlled, and longitudinallyinto a number of rows equal to the number of needle strokes in a patternon the finished carpet, the result being a number of unit areas ofpattern equal to the product of the said rows and columns, and aplurality of binary signalling parts in each unit.
 2. A machine patternas recited in claim 1, wherein said base is transparent and flexiblewith the parts of each unit area carrying a binary code of markingsadapted alternatively to transmit or block radiation.
 3. A machinepattern as recited in claim 1, wherein said base is reflective andflexible, the parts of each unit area carrying a binary code of markingsadapted alternatively to reflect or absorb radiation.
 4. A machinepattern as recited in claim 1, wherein said base is opaque and flexible,the parts of each unit area carrying a binary code punched through saidbase.
 5. A machine pattern as recited in claim 1, including asynchronizing means carried on at least one side thereof, the said meansbeing periodically recurring signalling areas.
 6. A method of producingand using a machine pattern as recited in claim 1, including the stepsof producing an artist''s pattern, applying a grid to said artist''spattern, said grid consisting of a number of unit areas equal to theproduct of the number of tufts in each row of a tufted carpet pattern tobe produced, and the number of columns of stitches in said pattern,producing a machine pattern consisting of a like number of unit areascontaining binary coded information corresponding to said artist''spattern, passing said machine pattern past a plurality of sensingdevices each of which senses the binary code of a unit area at one time,decoding the outputs of said sensing devices, and applying each decodedresults to control the supply of yarn to one needle of a tuftingmachine.
 7. A method as recited in claim 6, including the steps ofproducing a colored artist''s pattern, placing said grid with saidpattern in an adapted typewriter mechanism, applying a binary code tothe unit areas of said grid by means of said mechanism, and using saidcoded grid to control the colors of yarns fed to the needles of saidtufting machine to produce a tufted carpet with a pattern of tuftscolored to correspond with said artist''s pattern.
 8. A method asrecited in claim 6, including the steps of producing a colored artist''spattern, placing said grid with said pattern in a primary adaptedtypewriter mechanism, placing a machine pattern blank in a secondarymechanism synchronously operated with said primary mechanism, actuatingsaid primary mechanism so as to produce a series of binary coded unitareas on said machine pattern blank, and controlling the supply ofcolored yarns to the needles of said tufting machine by means of saidcoded machine pattern.
 9. A method as recited in claim 6, characterizedin that said machine pattern is transparent, with a binary code thereonof opaque parts, and including the steps of providing an illuminatingmeans and a plurality of photosensitive devices equal to the number oftufting machine needles to be controlled, and passing said machinepattern between said illuminating meaNs and said photosensitive devices.10. A method as recited in claim 6, wherein said machine pattern isreflective, with a binary code thereon of radiation absorbent parts, andincluding the steps of providing an illuminating means and a pluralityof photosensitive devices equal to the number of tufting machine needlesto be controlled, illuminating one side of said pattern by saidilluminating means, and sensing the radiation reflected from thereflecting parts thereof by means of said photosensitive devices.
 11. Amethod as recited in claim 6, wherein said machine pattern is an opaquesheet, and including the steps of punching said sheet in said unit areaswith a plurality of holes to produce a said binary codes.
 12. A methodas recited in claim 6, wherein said sensing devices are photoresistivecells, an integrated circuit and a transistor amplifiers connectionsfrom said cells to said amplifiers and integrated circuit, saidintegrated circuit decoding the combination of signals received fromsaid photoresistive cells to apply a potential to one of a plurality ofoutput leads, the lead energized determining the color of yarn to be fedto the associated tufting machine needle.